Method and system for interconnecting structural panels

ABSTRACT

Building or structural panels may be joined, such as to form walls or floors. The panels have edge anchors with mounts. The anchors may comprise elongate members defining a trough having spaced cross-pins. A connector is positioned between adjacent panels. The connector engages the mounts of the anchors, such by having the cross-pins slide into slots of the connector. The panels may have outer skins located over an expanded core comprising a matrix of supporting elongate members and voids or openings, with the anchors located slots formed in the edges of the panels.

RELATED APPLICATION DATA

This application is a continuation-in-part of U.S. patent applicationSer. No. 12/584,165, filed Aug. 31, 2009.

FIELD OF THE INVENTION

This invention relates to methods and systems for connecting structuralor building panels.

BACKGROUND OF THE INVENTION

Building panels have a wide variety of configurations. For example, somebuilding panels may comprise solid plywood or particle wood board. Thesepanels are heavy and utilize a substantial volume of material. Inaddition, such panels are often not very flexible, especially in thecase of particle board.

Various attempts have been made to construct other panels which arestronger and lighter in weight. For example, some panels have beenconstructed from metal. These panels, however, are very expensive bothbecause of the cost of the base materials and the production costs. Theyare also generally very strong, but not very light.

Some wood panels have been constructed with hollow cores or cores oflight-weight material. For example, some panels are constructed byapplying thin sheets of plywood to either side of a frame having an opencenter. In this configuration, the core or center of the panel ishollow. These panels are light-weight, but not very strong.

In order to increase the strength of these open-core type panels, foammay be sprayed into the interior or a paper honeycomb material may belocated in the interior. However, these panels have a number of otherdrawbacks. For example, these panels must be pre-constructed in aparticular size determined by the size of the frame. Once such a panelis constructed, it is not possible to change the size of the panel. Forexample, if such a panel is cut in half, the cut severs the supportingframe, causing one or more sides of the cut panels to have no structuralintegrity.

An improved panel which is light-weight, strong, and inexpensive, isdesired.

Another problem involves connecting building or structural panels. It iscommonly desired to couple multiple panels together to form walls,floors and the like. For example, at a convention a number of panels maybe connected to form a temporary wall to define a booth. An advantage ofusing pre-constructed panels is that large structures can be formed froma number of individual panels, each of which is relatively easy to moveand store. In addition, such structures can be formed in a non-permanentfashion, permitting the structure to be easily disassembled.

However, such structures must still be stable. In the case of panelswhich are used to form walls, the panels are generally placed uprightand aligned side-to-side. Because the panels are very thin, however,they are not self-supporting in the vertical position. The panels may beconnected to one another in a manner in which they maintain theirdesired position and form the desired structure. For example, panelsmight be connected with straps connected to the panels with connectors.This has the disadvantage that the straps may be visible and thefasteners may damage the panels, preventing them from being reused.Other means of connection include rotary locks embedded in the panelswhich can be rotated into engagement with a matting panel. Such locksare effective, but are costly and have a high installation cost.

Thus, an improved method and system for connecting panels is alsodesired.

SUMMARY OF THE INVENTION

One aspect of the invention is a method and system for joining buildingor structural panels. In one embodiment, the system comprises a firstanchor configured to be mounted at an edge of a first structural panel,a second anchor configured to be mounted at an edge of a secondstructural panel, and a connector. The first and second anchors maycomprise bodies which define a trough and have at least one mountextending into the trough. The connector comprises a body having a firstside and a second side, at least one first slot extending into the bodyfrom the first side and at least one second slot extending into the bodyfrom the second side. At least a portion of the first side of theconnector is configured to fit within the trough of the first anchorwhen the at least one mount of the first anchor is located in the atleast one first slot, and at least a portion of the second side of theconnector configured to fit within the trough of the second anchor whenthe at least one mount of the second anchor is located in the at leastone second slot, whereby the connector joins the first and secondanchors when connected thereto.

In one embodiment, the mounts comprise pins which extend across thetroughs. Each anchor may have a plurality of cross-pins and theconnector may include a corresponding number of slots for accepting thepins.

In one embodiment, the slots in the connector have a first portion thatextends laterally or transversely into the connector and a secondportion which extends perpendicular thereto (i.e. longitudinally alongthe connector). The slots in the first side of the connector may extendin an opposing direction from the slots in the second side. In thismanner, when the panels are oriented vertically, gravity maintains thepins in the slots of the connector.

The connector and the anchors may be sized so that when they areconnected, the connector is located inside of the anchors. In thismanner, the two connected panels may directly abut (rather than having aportion of the connector be exposed there between).

In an embodiment of a method, first and second panels are provided withanchors. The anchors are preferably located along edges of the panels.For example, the anchors may comprise elongate extrusions which arelocated in a slot formed in the edge of a panel. A connector is used toconnect the panels. In particular, the connector is engaged with themounts of the first and second anchors. So engaged, the panels aresecurely joined to one another.

Another aspect of the invention comprises a particular building paneland a method of making a building panel. The method and system forjoining or connecting panels has particular applicability to suchpanels, but may be used with panels of other configuration.

In one embodiment, a panel comprises a structural core and a pair ofouter skins or coverings. The core comprises a matrix of supportingmembers which surround or define voids or openings.

In a preferred embodiment, layers of building stock are connected to oneanother at specific locations. Each layer of building stock may comprisea thin layer of plywood. Each layer may comprise multiple pieces ofbuilding stock arranged end to end. Adhesive may be located at intervalsalong a length of the first layer of building stock. A second layer ofbuilding stock may then be connected to the first layer. This processmay be repeated until a stack is formed of multiple layers of buildingstock. The stack is cut into strips. Each strip may be rotated and thenexpanded. When expanded, the individual layers of building stockseparate in accordion fashion. Adjacent layers are selectively connectedat one or more locations and separate from one another at otherlocations to define openings or voids.

The core may be located between skins or coverings. The skins mightcomprise, for example, plywood sheets or lauan panels. The skins may beconnected to the core with adhesive.

The resulting panel is closed on each side or face by the skins. Theskins are supported by the structural core. The panel is strong andlightweight, owing to the hollow configuration of the core and theintertwined or interlaced structural members of the core. The panel maybe cut without jeopardizing the structural integrity of the core becauseof the unitary natural of the core.

In one embodiment, anchors or other elements may be associated with apanel. A slot may be formed in an edge of the panel, such as through theedge of the core between the skins. An elongate extruded anchor may beinserted into the slot. The anchor may be used to protect the edge ofthe panel and to mount the panel to other panels or other structures. Inanother embodiment, a slot may also be formed in the skin or face of thepanel and the core underlying the skin. Structural elements such asanchors or other elements may be located in such a slot at the face ofthe panel.

Further objects, features, and advantages of the present invention overthe prior art will become apparent from the detailed description of thedrawings which follows, when considered with the attached figures.

DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a first layer of building stock used to form a panelof the invention;

FIG. 1B illustrates first and second layers of building stock beingconnected to one another;

FIG. 1C illustrates a stack formed from a plurality of layers ofconnected building stock;

FIG. 1D illustrates the stack of FIG. 1C being cut into a plurality ofstrips;

FIG. 1E illustrates one of the strips cut from the stack illustrated inFIG. 1D;

FIG. 1F illustrates the strip of FIG. 1F being expanded into a core on ajig and located between top and bottom skins to form a panel of theinvention;

FIG. 1G illustrates a panel of the invention comprising a core locatedbetween a pair of skins;

FIG. 2A illustrates a panel anchor in accordance with an embodiment ofthe invention;

FIG. 2B illustrates another embodiment of a panel anchor;

FIG. 2C illustrates yet another embodiment of a panel anchor;

FIG. 3A illustrates a step of cutting an anchor slot into a panel;

FIG. 3B illustrates placement of an anchor into an anchor slot in apanel;

FIG. 3C illustrates a panel including a panel anchor;

FIG. 4 illustrates an anchor including connector mounts in accordancewith an embodiment of the invention;

FIG. 5 illustrates a panel connector in accordance with an embodiment ofthe invention;

FIG. 6 illustrates the inter-relationship of a connector and two panelsincluding anchors; and

FIG. 7 illustrates two panels connected to one another using a connectorand anchors in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, numerous specific details are set forth inorder to provide a more thorough description of the present invention.It will be apparent, however, to one skilled in the art, that thepresent invention may be practiced without these specific details. Inother instances, well-known features have not been described in detailso as not to obscure the invention.

One embodiment of the invention is a building panel. As will becomeapparent later, such panels may be used for a variety of purposes. Theuses of such panels are not intended to limit the scope of the inventionherein. For example, the panels of the invention may be used to formwalls or floors, or be used as doors, dividers or for other purposes.

In general, the panel of the invention has a core and a pair of opposingouter skins. The core preferably emulates a plant-like structure, havinga number of structural elements and open spaces or voids. Other aspectsof the invention comprise methods of making such panels, connectors forsuch panels, and methods of connecting panels.

One configuration of a panel of the invention will best be understoodfrom a method of making a panel in accordance with a preferredembodiment of the invention. Referring to FIG. 1, a first row or layer22 of building stock or material is provided. In a preferred embodiment,the building stock comprises plywood. Preferably, the building stock isgenerally planar, such as plywood having a thickness of 3 mm, 6 mm or 9mm. In one embodiment, the first layer 22 of building stock isconfigured with set dimensions. For example, the first layer 22 ofbuilding stock may be 48 inches wide. In order to arrange the buildingstock in this configuration, it may be cut from base stock. For example,48 inch by 48 inch plywood squares may be cut from base plywood sheetsthat are 48 inches wide by 96 inches long.

FIG. 1A illustrates a configuration in which the first layer 22 isformed from a plurality of individual building stock pieces 24 a,b,c. Asillustrated, each piece 24 a,b,c has dimensions of 48 inches by 48inches. The pieces 24 a,b,c are arranged into a row which is 48 incheswide by 144 inches long. In such a configuration, the pieces 24 a,b,care arranged end-to-end, with seams 26 at their intersections.Preferably, the pieces 24 a,b,c are arranged so that their verticalgrains align or extend parallel to one another. Of course, dependingupon the desired length of the panel to be created, the layers ofbuilding stock might comprise singular elements.

Referring to FIG. 1B, a second layer 28 of building stock is placed onthe first layer 22. Preferably, the second layer 28 is similar to thefirst layer 22. For example, the second layer 24 may be defined by aplurality of pieces 30 a,b,c,d of thin plywood stock. So that seams 32between the individual pieces forming the second layer 28 do not overlapwith the seams 26 of the first layer 22, they may be offset. This may beaccomplished by starting the second layer 24 with a shorter piece 30 a,such as a piece which is only 24 inches long. Of course, if the layerscomprise singular elements of building stock, no offset is necessary.

Referring to both FIGS. 1A and 1B, the second layer 28 is connected tothe first layer 22. In one embodiment, adhesive is utilized to connectthe layers of material. In a preferred embodiment, the layers areconnected at defined intervals. Referring to FIG. 1A, adhesive 34 may beapplied across the width of each piece 24 a,b,c at each end of the layerand at the midpoint of each piece 24 a,b,c. Thus, when the pieces are 48inches long, this means that the adhesive 28 is applied at 24 inchintervals, and the second layer 28 will thus be connected to the firstlayer 22 at such intervals. Of course, the layers 22,24 may be connectedat other intervals. As one example, if the first layer 24 is 96 incheslong, in one embodiment adhesive would be applied in 5 locations (at theends and 3 locations spaced 24 inches apart there between). In oneembodiment, the adhesive 34 is applied in a double line or strip at eachlocation. The adhesive 34 might comprise an exterior amphelic resinglue, preferably having an open working time of about 2 hours or more.

As illustrated in FIG. 1B, adhesive 34 may similarly be applied to thesecond layer 24 for connecting a third layer (not shown). The thirdlayer may be configured so that any seams between pieces forming thatlayer are again offset from the seams of the second layer and so thatthe adhesive joins are offset from those of the first layer. Thisprocess may be repeated until, as illustrated in FIG. 1C, a stack 36 isformed. This stack 36 comprises a plurality of individual layers ofbuilding material, those layers connected to one another at definedlocations. Preferably, the stack 36 is formed from multiple layers ofbuilding material. For example, the stack 36 might comprise as many as20 or more layers (there could be a lesser number of layers, or even asmany as 50 to 75 or more layers).

As illustrated in FIG. 1C, the stack 36 may be located in a press Pwhich compresses the rows or layers of material for a period of timewhich allows the adhesive to set or bond. This ensures that the rows orlayers of materials are securely joined. In one embodiment, the stack 36is compressed at 90 pounds per square inch for 8 to 12 hours.

As illustrated in FIG. 1D, the stack 36 is then cut into strips 38, asingle of which is illustrated in FIG. 1E. The strips 38 may havevarious widths. In one embodiment, the strips 38 are about 2 incheswide. In a configuration in which the stack 36 is 48 inches wide, about22 strips may be created from the stack 36 (some loss owing to cuttingof the stack). The stack 36 may be cut in various fashions. Asillustrated, in one embodiment, the stack 36 may be cut using a tablesaw.

Referring to FIG. 1F, each strip 38 may then be expanded. Asillustrated, the strip 38 may be rotated 90 degrees so that the layersof material forming the strip 38 are oriented vertically, rather thanhorizontally. The strip 38 may then be expanded in accordion-likefashion. As illustrated, the individual layers 22,28 of material areselectively joined at certain locations (at adhesive points) and freefrom one another at other locations (the areas between the adhesivejoins), the expanded strip thus forming a pattern or grid structurehaving openings or voids 40 therein.

As illustrated in FIG. 1F, the strip 38 may be expanded on a table orjig J. The jig J may comprise a planar support S having a plurality ofpositionable anchors or catches C. The catches C may comprise, forexample, metal pins. The strip 38 may then be connected to the catches Cat one side of the jig J and then pulled and expanded until it reachesthe other side of the jig J, where it is connected to the catches C tomaintain the strip 38 in an expanded position. The catches C arepreferably arranged to maintain the strip 38 in an expanded position ofa desired size. For example, the strip 38 may be expanded so that it is48 inches wide (the length of the strip 38 does not change substantiallybetween its expanded and unexpanded states, and is primarily governed bythe length of the stack 36 as constructed from the layers of buildingstock).

In its expanded state, the strip 38 comprises a core 40 for the panel ofthe invention. Additional details and aspects of the core 40 will bedescribed in more detail below.

As illustrated in FIG. 1G, exterior members, coverings or skins arepreferably applied to opposing sides of the core 40. In one embodiment,the skins are connected to the core 40 with adhesive. Adhesive isapplied to opposing sides of the core 40. The adhesive may be applied tothe expanded core 40, but is more easily applied to the strip 38 beforeit is expanded. In one embodiment, the adhesive is Reac Tite 8143 (asingle part moisture activated polyurethane) available from FranklinGlue or Utilithane 1600 (a two part polyurethane) by Prime Coatings,Inc.

Once the adhesive is applied, a first skin 42 may be applied to a firstside of the core 40, and a second skin 44 may be applied to the opposingsecond side of the core 40. In one embodiment, the first skin 42 may belocated on the jig J, as illustrated in FIG. 1F. The strip 38 may thenbe located over the first skin 42. The catches C are moved into positionand the strip 38 is connected to the catches C at one side of the jig J.The strip 38 is then expanded and held in position using the catches Cat the opposing side of the jig J. The second skin 44 may then beapplied over the expanded core 40.

The skins 42,44 may comprise a variety of materials. For example, theskins 42,44 might comprise thin plywood sheeting such as a lauan panel,a high pressure laminate (such as FORMICA®, a registered trademark ofFormica Corporation), an oriented strand board (OSB), plastic or PVCsheeting, aluminum or other metal, or other material. The skins 42,44might have one or more finished surfaces, such as an outer surface whichis stained, painted or the like.

After the skins 38 are attached, the assembly may be located in a press.The assembly of skins 42,44 and the core 40 may, for example, be heldunder 90 psi for 18 minutes, to allow the adhesive to set. The assemblymay then be removed from the pressed and allowed to cure, such as for aminimum of 4 hours. The assembly may be trimmed square, such as using adouble edge tenor or a CNC router.

The skins 42,44 preferably have a peripheral size which is substantiallythe same as the core 40. Thus, the length of the skins 42,44 isapproximately the same as the length of the core 40, and the width ofthe skins 42,44 is approximately the same as the width of the core 40.

Once the skins 42,44 are connected to the core 40, the combinationthereof comprises a panel 50. FIG. 1G illustrates the assembled panel50. A number of aspects of the panel 50 of the invention will now beappreciated. In one embodiment, the panel 50 comprises a pair of skins42,44 or coverings and an interior core 40. The skins 42,44 or coveringsdefine opposing sides or faces of the panel 50. The thickness of thepanel is determined by the thickness of each skin and the thickness ofthe core 40. The panel 50 has a periphery. When the panel 50 isquadrilateral in shape, it has four sides and thus four correspondingedges. As illustrated, the edges are generally defined by the core 40.At opposing ends of the panel 50, the connected and unconnected portionsof the layers of building stock which form the core are exposed. Atopposing side edges, the exterior-most layer of building stock formingthe core is visible. This exterior-most member undulates in and outtowards the edge of the panel 50 based upon the accordion configurationof the core 40.

For example, the panel 50 may be about 48 inches wide, 96 inches tall,and about 2.5 inches thick (depth). In that configuration, the skins42,44 and the core 40 all have a width of about 48 inches and a heightof about 96 inches. The core 40 may be 2 inches thick and the skins42,44 may each be about 0.25 inches thick.

The core has a number of important features. First, the core comprises aplurality of elongate members. These members comprise strip portions ofthe layers of building stock which were used to form the stack.Importantly, the elongate members are connected to one another in one ormore locations, thus comprising a matrix or grid structure. In addition,the core comprises openings or voids defined between the elongatemembers. These openings or voids lessen the mass of the core. Relativeto the expanded size of the core 40, the openings or voids may comprisea substantial volume of the space occupied by the core.

In a preferred embodiment, the structure of the core results in panel ofsubstantial strength. First, the elongate members run the length of thepanel from one end to another. In this manner, the members, and thus thecore, provide end to end strength for the panel. The elongate members,comprising strips of plywood or a similar material, also resistcompression. Thus, the core prevents the skins from being compressedtowards one another. Lastly, the elongate members are connected to oneanother across the width of the panel. In this manner, the core providedside-to-side strength of the panel. In addition, the skins add to thestrength of the panel.

Advantageously, the panels of the invention may be cut into variousshapes and sizes. The panels of the invention may also be connected toone another or other members or structures.

First, the panels may be cut. For example, a panel may be cut in halfalong its width or along its length. Importantly, regardless of how thepanel is cut, the strength and integrity of the divided portions of thepanel are maintained. This is because the core still remains in tact ineach divided portion of the panel. Thus, as to each divided portion ofthe panel, some part of the grid of elongate members which forms thecore exists therein, including along the newly formed edges of thedivided panel portions. This is unlike prior panel designs in whichcovers were located over a perimeter frame. In that prior artconfiguration if a panel was cut width-wise or length-wise, the portionsof the panel along the cut edge would have no structural integritybecause there would no longer be a supporting frame element along thatcut edge. An advantage of this aspect of the invention is that the panelcan be re-sized at a job site. As indicated, in the prior art, a panelhad to be custom-configured during manufacture. If the panel is shippedto a job and is the wrong size, the process must begin again with themanufacture of a new panel. However, in accordance with the presentinvention, a panel can be manufactured in a generic size and shipped toa job. The user can then cut the panel to any desired size for use invarious applications. In addition, a panel can be cut into a pluralityof sub-panels, thus creating multiple panels.

A substantial advantage of the invention is that the configuration ofeach panel core can be changed without changing the method ofmanufacture of the core. In particular, the extent to which a core isexpanded can be used to adjust the strength of the core and the densityor weight of the core. For example, a single stack might produce 10strips. A first strip might be expanded so that it is 48 inches inwidth. A second strip might be expanded so that it is 96 inches inwidth. If both cores are used with skins that are 48 inches in width,the second core will be cut in half. The first core will then have twiceas many supporting members than the second core, and likewise the secondcore will have twice as much void or open space therein. Thus, the firstcore will have a higher density and strength, but greater weight thatthe second core, and likewise the second core will be less strong but bemuch lighter than the first core. These two cores might be used indifferent applications where factors of weight or strength havedifferent levels of importance. In both cases, however, the stripsforming the core could be cut from the same stack.

In a preferred embodiment of the invention, the core of the panel has astructure which is similar to or emulates the xylem structure of aplant. In particular, the core has elongate structural members or fibersdefining or surrounding voids or openings. In one embodiment, thoseopenings are ogive-shaped. This structure allows the core to be loadbearing in both the vertical (top to bottom) and horizontal (side toside) direction.

The panels may be connected to one another and/or other members. Oneaspect of the invention comprises panel anchors 100 and methods ofanchoring panels. FIGS. 2A-2C illustrate various different anchors. Asillustrated in FIG. 2A, one anchor 100 a may comprise an elongateextruded metal (such as aluminum) member. In one embodiment, the anchor100 a has a top 102 and a bottom 104. The top 102 may be generally open,while the bottom 104 is generally closed. A pair of sides 106 a,b,extend from the bottom 104 towards the top 102. In this configuration,the anchor 100 a has the shape of a trough.

In the embodiment illustrated, the bottom 104 of the anchor 100 a isgenerally planar. The sides 106 a,b may comprise walls. The sides orwalls 106 a,b, preferably define a plurality of steps or protrusions.One or more of the portions of the walls 106 a,b may extend back towardsa center of the anchor 100 a. As detailed below, the configuration ofthe walls 106 a,b is preferably selected to prevent rotation of theanchor 100 a when it is placed in a panel 50.

Each side or wall 106 a,b defines an outwardly extending flange 110 atthe top 102 of the anchor 100 a. Each flange 110 preferably comprises agenerally planar area.

FIG. 2B illustrates another embodiment of an anchor 100 b. This anchor100 b may comprise a plastic extrusion. The anchor 100 b may again havea bottom and a top and a pair of walls. In this configuration, the wallsmay be generally vertical. To prevent rotation of the anchor 100 b, aplurality of fins 108 may extend outwardly from the walls.

FIG. 2C illustrates another embodiment of an anchor 100 c. This anchor100 c also comprises an extrusion. The anchor 100 c again has a bottomand a top and a pair of walls. Also, a number of flanges or extensions110 extend outwardly from a main body of the anchor 100 c for use insecuring the anchor 100 c, such as to prevent its rotation.

As illustrated, anchors 100 of the invention may include varioussurfaces or extensions which are configured to accept one or morefasteners. These fasteners may be used to secure the anchor to a panel.For example, while the anchor 100 may be configured to slide into achannel or slot and can not be removed laterally from the channel, thefasteners may be used to prevent the anchor from sliding back out of thechannel longitudinally.

It will be appreciated that the anchor 100 of the invention may haveother configurations.

A method of installing an anchor will be described with reference toFIGS. 3A-3C. As illustrated in FIG. 3A, in one embodiment, a slot 300 isformed in the edge of a panel 50. Notably, because of the strength andrigidity of the core 40 of the panel 50, an anchor can be installedalong any edge. For example, an anchor may be installed along a side ofa panel 50 (i.e. parallel to the direction that the elongate members ofthe core 40 extend) or along an end of a panel 50 (i.e. across the widthof the core 40). FIG. 3A illustrates one embodiment of the method inwhich a slot or channel 300 is formed in the core 50 along one side ofthe panel 50.

As illustrated, the slot 300 may be formed by passing a cutter 302 alongthe side of the panel 50. The cutter 302 preferably has a profile whichmatches the anchor to be installed. For example, the cutter 302 may be arotary bit, such as a router bit. The cutter 302 passes through the core40 along its length adjacent the side of the panel 50.

As illustrated in FIG. 3B, a corresponding anchor 100 may be located inthe slot 300, such as by sliding the elongate anchor 100 into the slot300. This sliding engagement has the advantage that it allows very quickinstallation of the anchor. Further, because the slot 300 and anchor 100are formed with inter-engaging members, the anchor 100 is self-centeringor aligning, again allowing it to be quickly and easily installed.

In a preferred embodiment, the slot or channel 300 includes protrusionswhich extend into the slot. These protrusions preferably engage theanchor 100, such as between flanges of the anchor. Thisinter-engagement, similar to a tongue and groove or similar lockingconfiguration, secures the anchor to the panel along the length of theanchor. This provides greater mounting strength than, for example,merely gluing or connecting a member to the panel with individualfasteners.

Referring to FIG. 3C, once the anchor 100 is placed, the flanges 110 atthe top 102 thereof protect the surrounding portions of the panel 50.The anchor 100 is also prevented from rotating within the slot 300 orfrom being pulled outwardly from the slot 300 because the protrudingportions thereof are located in corresponding cut-out areas of the slot300. As indicated above, one or more fasteners, adhesive or the like maybe used to prevent the anchor from sliding longitudinally along theslot.

Notably, the anchor 100 extends along the length of the edge of thepanel 50, thus protecting that edge of the panel from damage and alsoadding strength to the panel. In particular, the anchor 100 serves as anedge protector: the flanges and other portions of the anchor serve toprotect the edge of the panel from damage. The anchor 100 alsostrengthens the panel 50 by extending along its outer edge, addingrigidity to the panel 50. In the configuration in which the anchor 100is located in a slot 300 and engages the panel 50, the anchor 100becomes an integral portion of the panel 50, rather than merely anelement which is attached to or affixed to the outside of the panel andcarried by the panel.

It is noted that the anchors 100 may be formed in elongate extrusions.Those extrusions may be cut to a length which matches the length of theedge of a panel 50 to which the anchor 100 is to be mounted.

As disclosed below, the anchor 100 may also be used to connect or mountthe panel 50 to one another members.

It will be appreciated that anchors may be utilized which are notextruded and/or which do not extend the entire length of the edge orside of a panel. For example, short anchor members might be located atjust the top and bottom portions of an edge of the panel (such thatthere is no anchor member in the center portion of the edge).

Because of the structure of the panel of the invention, it is alsopossible to utilize other types of anchors or mounts. For example, a “T”shaped slot may be routed or otherwise formed in the top or bottom skin42,44 and adjacent core structure 40. A “T” shaped extrusion may beslipped into this slot and may be connected with adhesive or the like tothe panel.

The panel of the invention also permits mounting of items to the skins42,44. For example, a passage may be formed through the core 40laterally to the mounting point. A dowel or peg may be placed into thatpassage for intersection with the mount which extends through the skin42,44 into the core. The dowel or peg is supported by the structure ofthe core and thus provide substantial support for the mount whichextends through the skin 42,44.

One advantage of the panel of the invention is that it ready permitsformation of a structural slot or channel. This slot is capable ofsupporting an anchor or other element. The anchor may be used to connectthe panel to another panel or other structure/member. The anchor mayalso be used as an edge protector.

The slot in the panel and/or the anchors may be used to mount anassortment of fasteners or connectors. One or more fasteners may beattached to the anchors and be located in the slot or trough thereof,such as one or more Norse locks or Simmons locks. The trough or slot ofthe anchor may also be designed to accept standard shelf support, T-slotbrackets and similar off-readily available/off the shelf connectors andmounts. For example, the anchors may be configured to accept rotary typelocks such as those shown in U.S. Pat. Nos. 5,480,117 and 5,601,266 tothe inventor herein. Such fasteners or connectors may be used to connectone panel to another in a secure manner, thus enabling multipleindividual panels to be joined into wall sections and otherconfigurations, and/or permitting the panels to be connected to othermembers or structures.

A particular advantage of the invention is that the structural slot andanchor may be associated with a panel after the panel is manufactured,and even after a panel has been cut. In the prior art an anchor might beassociated with a frame of a panel during the manufacture of the panel.However, if that prior art panel is cut, a portion of the frame and thusthe associated anchor, may be severed from the panel, rendering ituseless. However, the panel of the invention can be cut and a slot orchannel can be formed in any portion or the panel at any time (either inan edge or even in a face or skin thereof, as detailed above). Thus, apanel can be cut and slots can be formed in the new edges of both newpanel portions. Anchors can then be located in those slots, wherebycustom configured panels with anchors can easily be formed at a jobsite.

Another aspect of the invention comprises a preferred method and systemfor connecting panels. Such a method and system have particularapplicability to the panels described herein, but may be utilizedrelative to a wide range of panels other than those of the invention,such as prior art “frame” panels. As described above, there areparticular advantages associated with connecting pre-constructed panels.

In one embodiment, a method and system of connecting panels comprisesmounting anchors to panels and then using one or more connectors toconnect the panels via the anchors. Referring to FIG. 4, in oneembodiment, the anchors 100 comprise a channel or mounting member, suchas described above. Such an anchor 100 is preferably securely mounted atan edge or side of the panel P. The anchor 100 may have configurationsother than that described above.

Preferably, each anchor 100 includes one or more mounts 120. The mounts120 are configured to accept or engage a connector. In one embodiment,the mounts 120 may comprise a pin, such as a pin which spans the trough102 of the anchor 100. The mounts 120 might have other configurations,however, such as members which protrude from the anchors. The mounts 120may have a uniform spacing or configuration for acceptance of astandardized connector, as detailed below. For example, the mounts 120might be uniformly located 30 cm apart.

In one embodiment, a connector 150 is used to connect panels P outfittedwith anchors. The connector 150 preferably comprises a body which isconfigured to engage one or more of the mounts 120 of the anchors 100 ofthe panels P and serves to connect the two panels.

One embodiment of a connector 150 is illustrated in detail in FIG. 5. Inthis embodiment, the connector 150 comprises a generally planar body152. The body 152 has a front and a back and a pair of opposing sides154 a,b. The body 152 also has a top 156 and a bottom 158. The connector150 might be constructed from wood or synthetic materials.

The connector 150 is configured to engage one or more mounts 120. In oneembodiment, the connector 150 defines one or more slots 160. Each slot160 preferably extends inwardly from one of the sides 154 a,b of thebody 152. Each slot 160 preferably defines an opening 162 located at oneof the sides 154 a,b of the body 152. Each slot 160 has a terminus orclosed portion 164 defined in the body 152.

In a preferred embodiment, the first or opening 162 portion of each slot160 extends generally laterally or transversely into the body 156 (i.e.towards the opposing side). The terminus or closed portion 164 ispreferably defined by generally vertically or longitudinally extendingportion of the slot (i.e. a portion which extends generallyperpendicular to the opening portion and thus generally in the directionparallel to a line extending through the ends of the connector).

In a preferred embodiment, the longitudinal portions of the slots 160 atopposing sides 154 a,b of the body 152 extend in opposing directions. Inthe example illustrated in FIG. 5, the slots 160 associated with thefirst side 154 a have their longitudinal or terminating section 164extending upwardly from the opening portion 162. On the other hand, theslots 160 associated with the second side 154 b have their longitudinalor terminating section 164 extending downwardly (in the opposingdirection). Of course, the orientation of the slots 160 at the opposingsides could be reversed from that illustrated.

Additional details of the anchors 100 and the connector 150 will beappreciated when considering FIGS. 6 and 7, which shows the manner ofconnecting two panels P. As illustrated therein, anchors 100 areassociated with at least two edges of the panels P. Preferably, theanchors 100 are associated with at least edge of the panels P which areoriented towards one another when the panels are in their desiredorientation. In this configuration the panels P are oriented to thatedges having anchors 100 face one another, as illustrated in FIG. 6.

A connector 150 is used to connect the panels P. As illustrated, theconnector 150 is located between the edges of the panels P beingconnected. The connector 150 is oriented so that one side 154 a thereoffaces one of the panels P and the other side 154 b faces the other panelP.

The connector 150 is connected to the two anchors 100. As illustrated,the connector 150 is positioned so that the openings 162 of the slots160 at one side 154 a of the connector 150 are aligned with the mounts120 of one of the anchors 100. The connector 150 and panel P can then bemoved relative to one another so that the mounts 120 move into thelongitudinal closed portions 162 of the slots 160. The same process isrepeated relative to the slots 160 at the second side 154 b of theconnector 150 relative to the other panel.

As illustrated in FIG. 7, once the connector 150 is so positioned, it islocated between and housed within the panels P. The edges of the panelsP are positioned adjacent to one another with the connector 150 joiningthe panels P.

From FIG. 7 it will be appreciated that the configuration of the anchors100, position of the mounts 120 and the shape and configuration of theconnector 150 are all preferably selected to achieve a number ofresults. In a preferred embodiment, the anchors 100 and the connector150 are sized so that the connector 150 fits within the anchors 100 whenmounted thereto (i.e. so that the edges of the panels P abut when theyare connected and the connector 150 is not exposed in a space betweenthem). The mounts 120 and the slots 160 are positioned so that theyalign in mating configuration, as illustrated (it being appreciated thata misplaced anchor or slot would prevent mating thereof—as indicated, ifthe mounts 120 are located 30 cm apart, then the corresponding slots 160are similarly spaced). The depth of the mounts 120 within the anchors120 and the depth of the slots 160 are chosen so that the mounts 120 fitwithin the slots 160 when the connector 150 is accepted into the anchors100.

It will be appreciated that two or more anchors could be associated witha panel. For example, while one single long anchor could be located atan edge of a panel, two or more shorter anchors could be associated withthat edge. Similarly, one or more connectors could join to one or moreanchors. In a preferred embodiment, a single long anchor is located ateach panel edge (the anchor extending generally along the entire lengthof the panel) and the connector similarly extends along the entirelength of the anchors of one or more panels.

It will also be appreciated that anchors 100 may be located along morethan one edge of a panel P. For example, anchors 100 may be located atopposing edges of a panel or all four edges of a panel. So configured,panels P may be joined to other panels P in a variety of orientations.For example, panels P may be joined side-to-side to form a wall.However, the panels P might be connected in a grid, such as a matrix ofn×m panels, such as to form a floor or a wall which is more than onepanel in height.

The number of mounts 120 associated with an anchor 100 may vary. Forexample, an anchor 100 might have only one mount 120 or might have aplurality of mounts. Of course, the number of slots 160 a connector 150has may be depend upon the number of mounts 120 it is to connect to. Theslots 160 may taper or narrow at their terminus, thus causing the mountsto wedge or fit tightly in the slots 160 in their connected position.

This method and system for connecting panels has substantial benefitsover known techniques. One aspect of the method and system is that it isconfigured so that the force of gravity locks the panels into theirconnected position. In this manner, the method of joining or connectingthe panels may be referred to as a gravity mount or connection, with theconnector referred to as a gravity cleat. As illustrated in FIG. 7, theconfiguration of the mounts and slots, including their inverseorientation at opposing sides of the connector, causes gravity to movethe panels and connector into maximum locking position. In particular,the weight of the right-side panel P causes the panel (and thusassociated mounts 120) to move to the bottom of the slots 160 at thatside 154 b of the connector 150). This, in turn, pulls the entireconnector 150 down, causing the mounts 120 at the opposing side to bepositioned at the tops of the slots 160 in the opposing side 154 a ofthe connector 150. In this manner, maximum locking effect is realizedbetween the panels P and the connector 150.

A particular advantage of the method and system is that the connector150 can be installed and the connection can be accomplished without theneed for tools. Once panels P are outfitted with anchors, they can bejoined merely by orienting the panels and placing the connector(s) 150between them. This greatly reduces the time and energy needed toconnected and disconnect panels, and simplifies that process. Further,when the anchors and connectors are standardized in their configuration,various panels can be connected in various orientations with anyconnector. This again greatly simplifies the connection of panels.

Another particular advantage is that the connector 150 can be used toconnect panels which are outfitted with anchors for various purposes.For example, panels P may be outfitted with anchors at least partiallyto protect the edges thereof. However, once installed, those anchorsserver as a convenient means to join panels at any time, merely byengaging the connectors therewith.

It will be understood that the above described arrangements of apparatusand the method there from are merely illustrative of applications of theprinciples of this invention and many other embodiments andmodifications may be made without departing from the spirit and scope ofthe invention as defined in the claims.

What is claimed is:
 1. A method of forming a structure comprising thesteps of: providing a first structural panel having a first edge and afirst anchor located at said first edge, said first anchor defining atleast one first mount; providing a second structural panel having asecond edge and a second anchor located at said second edge, said secondanchor defining at least one second mount; providing a connector havinga least two slots therein; positioning said connector between said firstand second structural panels; locating said at least one first mount inat least one of said at least two slots of said connector; and locatingsaid at least one second mount in at least one of said at least twoslots of said connector; whereby said first edge of said firststructural panel is positioned adjacent said second edge of said secondstructural panel, with said connector engaging said first anchor andsecond anchor, joining said panels into a structure.
 2. The method inaccordance with claim 1 wherein said first anchor comprises an elongatebody defining a trough and said at least one first mount comprises a pinextending into said trough.
 3. The method in accordance with claim 2wherein said second anchor comprises an elongate body defining a troughand said at least one second mount comprises a pin extending into saidtrough.
 4. The method in accordance with claim 3 wherein said connectorhas a first side and a second side and comprising the step of locatingsaid first side in said trough of said first anchor and locating saidsecond side in said trough of said second anchor.
 5. The method inaccordance with claim 1 wherein said first structural panel comprises apair of skins located at opposing sides of an expanded core and saidsecond structural panel comprises a pair of skins located at opposingsides of an expanded core.
 6. The method in accordance with claim 1wherein said connector has a first side and a second side, at least onefirst slot extending into said first side and at least one second slotextending into said second side and comprising locating said at leastone first mount in said at least one first slot and locating said atleast one second mount in said at least one second slot.
 7. A system forconnecting a first structural panel and a second structural panelcomprising: a first anchor configured to be mounted at an edge of saidfirst structural panel, said first anchor comprising a body defining atrough and comprising at least one mount extending into said trough; asecond anchor configured to be mounted at an edge of a second structuralpanel, said second anchor comprising a body defining a trough andcomprising at least one mount extending into said trough; and aconnector, said connector comprising a body having a first side and asecond side, at least one first slot extending into said body from saidfirst side and at least one second slot extending into said body fromsaid second side, at least a portion of said first side of saidconnector configured to fit within said trough of said first anchor whensaid at least one mount of said first anchor is located in said at leastone first slot, and at least a portion of said second side of saidconnector configured to fit within said trough of said second anchorwhen said at least one mount of said second anchor is located in said atleast one second slot, whereby said connector joins said first andsecond anchors when connected thereto.
 8. The system in accordance withclaim 7 wherein said bodies of said first and second anchors compriseelongate extrusions.
 9. The system in accordance with claim 7 whereinsaid at least one mount extending in to said trough of said first anchorcomprises a pin.
 10. The system in accordance with claim 9 wherein saidpin spans said trough.
 11. The system in accordance with claim 9 whereinsaid at least one first slot has a first portion extending generallytransversely into said body from said first side and a second portionextending from said first portion, said second portion extendinggenerally perpendicular to said first portion.
 12. The system inaccordance with claim 11 wherein said at least one second slot has afirst portion extending generally transversely into said body from saidfirst side and a second portion extending from said first portion, saidsecond portion extending generally perpendicular to said first portion.13. The system in accordance with claim 12 wherein said second portionof said first slot extends from said first portion of said first slot ina first direction and said second portion of said second slot extendsfrom said second portion of said second slot in a second direction whichis generally opposite said first direction.
 14. The system in accordancewith claim 7 wherein said first anchor has a plurality of mounts andsaid connector has a plurality of first slots corresponding to each ofsaid mounts
 15. The system in accordance with claim 14 wherein saidsecond anchor has a plurality of mounts and said connector has aplurality of second slots corresponding to each of said mounts.
 16. Thesystem in accordance with claim 7 wherein said first and second anchorsare configured to be located in a channel located in said edge of eachof said first and second structural panels.
 17. The system in accordancewith claim 7 wherein a width of said connector between said first andsecond sides thereof an a depth of said trough of said first anchor anda depth of said trough of said second anchor are selected so that whensaid connector is mounted to said first and second anchors, said firstand second anchors abut with said connector located therein.